Festo CP Factory User manual

Festo Didactic
CP Factory / CP Lab
06/2017
CP Factory / CP Lab®
Manual
application module iDrilling

2© Festo Didactic CP Factory / CP Lab ° application module drilling
Order-No.:
Date: 06/2017
Layout: 06/2017, Schober
Filename: CP-AM-iDRILL-GB-A001.doc
© Festo Didactic SE, 73770 Denkendorf, Germany, 2017
Internet: www.festo-didactic.com
E-Mail: [email protected]m
Note
Where only pronouns such as he and him are used in this manual, these pronouns are of course
intended to refer to both male and female persons. The use of a single gender should not be
construed as gender discrimination; it’s intended solely to make the manual easier to read and the
formulations easier to understand.
Intended use
This installation was developed and manufactured for use in basic and further training in the fields
of automation and communications. The training company and/or the training staff must ensure
that the trainees observe the safety precautions.
Festo Didactic accepts no liability for injury or harm to trainees, the training company and/or any
third parties occurring when the installation is used for any purpose apart from training, except
Festo Didactic has caused such injury or harm intentionally or by grossly negligence.
At CP factory installations, it is not permissible to experiment with hazardous live voltages.
Reproduction, distribution and utilisation of this document, as well as the communication of its
contents to others without explicit authorisation, are prohibited. Offenders shall be held liable for
payment of damages. All rights reserved, in particular the right to file patent, utility model and
registered design applications.
Furthermore this manual describes setup and possible uses of the singular stations. It contains all
information and data required for commissioning, maintenance and operation.

Content
© Festo Didactic CP Factory / CP Lab ° application module drilling 3
Content
1 General safety instructions __________________________________________________________________ 5
1.1 Pictograms ___________________________________________________________________________ 6
1.2 Safety sockets_________________________________________________________________________ 7
1.3 Note to electrical access of facility ________________________________________________________ 7
1.4 Handling the system ___________________________________________________________________ 8
1.4.1 Dangers in handling the machine _____________________________________________________ 8
1.4.2 Safety precautions in standard operation ______________________________________________ 8
1.4.3 Dangers due to electric current _______________________________________________________ 8
1.4.4 Dangers due to pneumatic energy ____________________________________________________ 8
1.4.5 Maintenance –Servicing –Malfunction removal _________________________________________ 8
1.4.6 Organizational measures ____________________________________________________________ 9
1.5 Personnel ____________________________________________________________________________ 9
1.5.1 Notes on personnel_________________________________________________________________ 9
1.5.2 Training operations_________________________________________________________________ 9
1.5.3 Outside training operations __________________________________________________________ 9
1.6 Obligations of the operating company _____________________________________________________ 9
1.7 Obligations of the trainees ______________________________________________________________ 9
2 Introduction _____________________________________________________________________________ 10
2.1 Warranty and liability__________________________________________________________________ 10
2.2 Important notes ______________________________________________________________________ 10
3 Technical data ___________________________________________________________________________ 11
4 Design and function_______________________________________________________________________ 12
4.1 Transport____________________________________________________________________________ 12
4.2 Set up ______________________________________________________________________________ 12
4.2.1 General information _______________________________________________________________ 12
4.3 The application module iDrilling _________________________________________________________ 13
4.4 Function_____________________________________________________________________________ 15
4.5 Process description ___________________________________________________________________ 16
4.6 Electrical Connections _________________________________________________________________ 17
4.6.1 CECC I/O assignment ______________________________________________________________ 17
5 Start up_________________________________________________________________________________ 19
5.1 Workstation__________________________________________________________________________ 19
5.2 Mechanical Setup_____________________________________________________________________ 19
5.2.1 Connection of application module____________________________________________________ 20
5.2.2 Pneumatic port of application module ________________________________________________ 22
5.2.3 Electrical connection of application modules ___________________________________________ 22
5.3 Adjusting the sensors _________________________________________________________________ 23
5.3.1 Through-beam sensor (Workpiece detection) __________________________________________ 23
5.3.2 Proximity Switch (X-axis cylinder) ____________________________________________________ 25
5.3.3 Proximity switch (Z-axis)____________________________________________________________ 27
5.4 Adjusting the one-way flow control valves_________________________________________________ 29
5.5 Visual inspection _____________________________________________________________________ 30
6 Operation _______________________________________________________________________________ 31
6.1 General operating instructions __________________________________________________________ 31

Content
4© Festo Didactic CP Factory / CP Lab ° application module drilling
6.1.1 Conduct instructions_______________________________________________________________ 31
6.1.2 Operating instructions _____________________________________________________________ 31
6.2 Sequence description of the application module drilling _____________________________________ 31
6.3 Setting the application module drilling at HMI _____________________________________________ 35
6.4 Transitions of the application module ____________________________________________________ 37
6.5 Parameter of application _______________________________________________________________ 38

General safety instructions
© Festo Didactic CP Factory / CP Lab ° application module drilling 5
1General safety instructions
The laboratory or the classroom must be equipped in accordance with EN 50191:
An emergency off device must be provided.
–At least one emergency off device must be located within, and one outside of the test area.
The test area must be secured against unauthorised start-up.
–For example with a key switch
The test area must be protected by residual current devices (RCDs).
–Type B residual current circuit breaker with a residual current rating of ≤ 30 mA
The test area must be protected by overcurrent protection devices.
–Fuses or circuit breakers
The test area must be overseen by a supervisor.
–A supervisor is a qualified electrician or a person who has received appropriate instruction, has
knowledge of the respective safety requirements and safety regulations and whose training has been
accordingly documented.
No damaged or defective devices may be used.
–Damaged devices must be barred from further use and removed from the test area.
General requirements for safe operation of the devices:
Do not lay cables over hot surfaces.
–Hot surfaces are identified with a corresponding warning symbol.
Maximum permissible current loads for cables and devices must not be exceeded.
–Always compare the current ratings of the device, the cable and the fuse.
–In the event that these are not the same, use a separate upstream fuse in order to provide
appropriate overcurrent protection.
Devices with an earth terminal must always be grounded.
–If an earth connection (green-yellow laboratory socket) is available, it must always be connected to
protective earth. Protective earth must always be connected first (before voltage), and must always be
disconnected last (after voltage).
If not otherwise specified in the technical data, the device is not equipped with an integrated fuse.

General safety instructions
6© Festo Didactic CP Factory / CP Lab ° application module drilling
1.1 Pictograms
This document and the described hardware include warnings concerning possible hazards which may arise if
the system is used incorrectly. The following pictograms are used:
Warning
Non-observance of this pictogram may result in serious personal injury or damage
to property.
Caution
Non-observance of this pictogram may result in personal injury or damage to
property.
Warning
This pictogram indicates that the device must be switched off and its mains plug
must be removed from the electrical outlet before installation, repair, maintenance
and cleaning work. Observe the manual, in particular all safety instructions. Non-
observance may result in severe personal injury or damage to property.
Warning
This pictogram indicates danger of being burned if hot surfaces (up to roughly
85 C) are touched.
Important
This symbol emphasizes important information for correct machine handling.
Failure to pay attention to this symbol may result in damages to the machine or to
its surroundings.
i
Information
This symbol indicates operational tips and especially useful directions. This
symbol assists you to make optimal use of all of your machine’s functions.

General safety instructions
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1.2 Safety sockets
If not otherwise specified in the technical data, the following colour codes apply to the power supply and
signal connections for components included in Festo Didactic’s learning system for automation and
technology.
Colour
Function
Colour
Function
Voltage greater than SELV
e.g. line voltage of 90 to 400 V AC per conductor
(grey)
24 V DC
(red)
Neutral conductor
(grey/blue)
0 V DC
(blue)
Protective conductor
(green-yellow)
Safety extra-low voltage,
signal input/output
(black)
The specified protection class and safe use can only be assured if laboratory safety cables supplied by Festo
Didactic are used.
Damaged laboratory safety cables must be immediately barred from further use
and removed from the test area.
1.3 Note to electrical access of facility
According to EN 60204-1 (VDE 0113-1) part 8.2.8, a supply cable with an additional protective conductor is
required for the supply of the CP factory installations. Since a leakage current of >10mA can flow depending
on the configuration, an additional protective conductor with 10mm² is necessary.
Please see also DIN EN 60204-1.

General safety instructions
8© Festo Didactic CP Factory / CP Lab ° application module drilling
1.4 Handling the system
1.4.1 Dangers in handling the machine
The installation has been constructed technologically up to date and in conformance with the recognized
rules of safety engineering. Nevertheless, during operation it is possible that harm might be caused to the
user or third parties or that the installation or other property might get damaged. Therefore, the installation
has to be handled according to specified operational use in perfect technical condition only.
Safety endangering malfunctions cannot be tolerated during training and have to be removed immediately.
The system is to be used only:
for its intended purpose and
In absolutely safe conditions.
Faults impairing safety must be rectified immediately!
1.4.2 Safety precautions in standard operation
Put the installation into operation only, once all of the protection settings are completely functional.
At least, before starting operation, check the installation for externally visible damages and for the reliability
of the safety devices.
Do not grip into the installation while in operation.
Before circuit construction, circuit disassembly and circuit modification: switch off air pressure and power
supply.
General safety regulations are to be observed: DIN 58126 and VDE 0100.
1.4.3 Dangers due to electric current
As soon as maintenance is completed, check the function reliability of the safety devices.
Only trained experts in electric or electronic engineering are permitted to carry out work on the electric
supply system.
The terminal boxes are to be kept closed at all times. Access must be permitted only under supervision of a
member of the training staff.
Do not activate electric limit switches manually during fault search. Tools are to be used.
Only low voltage 24VDC is to be used.
1.4.4 Dangers due to pneumatic energy
Accidents might occur due to bouncing off tubes, caused by air pressure. Interrupt air pressure supply
immediately. Caution! When the air pressure supply is activated, cylinders may move in or out.
Do not uncouple any tubes under air pressure supply. Exception: Fault finding. In this case, keep on holding
the end of the tube. Do not exceed the permitted operating pressure. See data sheets.
1.4.5 Maintenance –Servicing –Malfunction removal
Carry out adjustments and inspections as instructed, in accordance with the specified intervals. (see
Datasheets)
Secure the compressed air and electricity supplies to prevent unintentional start-up. During inspections,
maintenance and repair work, the machine must be de-energized, de-pressurized and secured against
unexpected restart. All screw connections released during maintenance, inspection or repair work must be
checked to ensure correct re-tightening.

General safety instructions
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1.4.6 Organizational measures
All existing safety devices must be checked at regular intervals.
1.5 Personnel
1.5.1 Notes on personnel
Basically two situations have to be considered, concerning matters on personnel.
Activities during training operations
Activities outside training operations
1.5.2 Training operations
Trainees are permitted to work with the machine only under strict supervision of an experienced person or
an instructor.
Activities of trouble-shooting and fault correction are to be checked by the instructor. Special care should be
taken regarding safety aspects.
1.5.3 Outside training operations
Activities in the areas of maintenance, service and repair are to be carried out by only persons with
appropriate technical qualifications.
1.6 Obligations of the operating company
The operating company undertakes to allow only those persons to work with the system who:
Are familiar with the basic regulations regarding work safety and accident prevention and have been
instructed in the use of the system
Have read and understood the chapter concerning safety and the warnings in this manual
Personnel should be tested at regular intervals for safety-conscious work habits.
1.7 Obligations of the trainees
All persons who have been entrusted to work with the system undertake to complete the following steps
before beginning work:
Read the chapter concerning safety and the warnings in this manual
Observe the basic regulations on occupational safety and accident prevention.

Introduction
10 © Festo Didactic CP Factory / CP Lab ° application module drilling
2Introduction
2.1 Warranty and liability
In principle all our „Terms and Conditions of Sale“ apply. These are available to the operating authority
upon conclusion of the contract at the latest. Warranty and liability claims for persons or material damage
are excluded if these can be traced back to one or several of the following causes:
Use of the system not in accordance with its intended purpose
Incorrect assembly, commissioning, operation and maintenance of the system
Operation of the system using faulty safety equipment or incorrectly fitted or non-operational safety or
protective devices
Non observance of notes in the manual regarding transport, storage, assembly, commissioning,
operation, maintenance and setting up of the system
Unlawful constructional modifications on the system
Inadequate monitoring of components subject to wear
Incorrectly carried out repairs
Catastrophes as a result of foreign bodies and vis major.
Festo Didactic herewith rules out any liability for damage or injury to trainees, the training company and/or
other third parties which may occur during the use/operation of the system other than purely in a training
situation, unless such damage has been caused intentionally or due to gross negligence by Festo Didactic.
2.2 Important notes
The basic requirement for safe use and trouble-free operation of the system is to observe the fundamental
safety recommendations and regulations.
This manual contains important notes concerning the safe operation of the system.
The safety recommendations in particular must be observed by anyone working on the system.
Furthermore, the rules and regulations for the prevention of accidents applicable to the place of use must be
observed.

Introduction
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3Technical data
Parameter
Value
Operating pressure
600 kPA ( 6 bar)
Power supply
24 V DC, 4.5 A
L x W x H
382 x 215 x 574 mm
Weight
approx 5 kg
Digital inputs
7
Digital output
7

Design and function
12 © Festo Didactic CP Factory / CP Lab ° application module drilling
4Design and function
4.1 Transport
Care is to be taken that the transport of the stations is to be executed only by a suitable transport vehicle.
The weight amounts up to 500 kg, depending on the station.
The route of transport is to be cleared in advance, to be accessible to the transport vehicle. Installation of
warning signs or barriers may be required.
The transport boxes are to be opened with care, as additional components, such as computers may be
contained in the delivery, which are to be protected from falling out.
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Once the transport box has been opened and the possibly contained additional
components removed, the station can be taken out to be transported to its destination by
means of two fork-lifts or one fork-lift truck.
Please check the stability of all of the profile connectors by means of an Allen key size 6.
The connectors may have come loose during transport, due to inevitable vibration.
Once the transport box has been opened and the possibly contained additional
components removed, the station can be taken out to be transported to its destination by
means of two fork-lifts or one fork-lift truck.
Please check the stability of all of the profile connectors by means of an Allen key size 6.
The connectors may have come loose during transport, due to inevitable vibration.
Pay special attention to all overhanging components. Sensors and similar small parts are
very easily damaged in case of improper transport.
The stations are not to be picked up by or even under the mounted feet –increased risk of
becoming trapped or contused.
Check the station for any possible damaged once unpacked. The carrier and Festo Didactic
are to be notified immediately of any damage.
4.2 Set up
4.2.1 General information
The installation is to be set up in a frost-free room with maximum relative air humidity of 70%.
In countries with an atmospheric humidity over 70% and temperatures above 25 degrees Celsius are the
premises to provide an air-conditioning system for constant surroundings conditions.
To comply with the regulatory guidelines, sources of electrical interference such as welding plants, large
motors and contactors are to be checked for electromagnetic compatibility in advance and screened where
necessary.
To ensure fault-free operation a load-bearing floor is required to avoid settling.
Allow sufficient distance between the installation and the wall of the room.
Any dust originating from construction work has to be kept off the installation (by covering).

Design and function
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4.3 The application module iDrilling
The application module iDrilling is designed for
Providing a housing lower part with 4 drilled holes. During this, it is queried whether it is placed correctly
without cover. The drilling unit will make 2 drilled holes into the left part of the housing lower part. Then
the drilling unit will be moved to the right by an X-axis, and the additional 2 holes will be drilled.

Design and function
14 © Festo Didactic CP Factory / CP Lab ° application module drilling
Position
Description
Part name
Order number
1
PLC
CECC-LK
574418
2
Valve terminal
80P-10-1LIH-PB-N-SLC-4JK-T
525675
3
Start-up current limiter 1
150768
4
guiding X-axis
DGC-12-120-KF-YSR-A
530907
5
Z-axis
DGSL-10-40-E3-Y3A
543905
6
Z-axis clamping
DGSL-10-40-E3-Y3A
543905
7
X-axis driven
DGC-12-120-KF-YSR-A
530907
8
Workpiece request (lower part in correct position)
SOEZ-LLK-SE-2,0-M4
165360
9
Workpiece request (no upper part available)
SOEZ-LLK-SE-2,0-M4
165360
10
Workpiece request (workpiece available)
SOEZ-LLK-SE-2,0-M4
165360
11
Start-up current limiter 2
150768
12
Drill 2
drill construction kit
656874
13
Drill 1
drill construction kit
656874

Design and function
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4.4 Function
The application module iDrilling drills 4 drilling holes into the lower part of the housing. The workpieces are
recognized by the first light barrier when moving into the application module iDrilling and the carrier will be
stopped. When the carrier has been stopped, the workpiece will be checked. The workpiece request (3)
checks if there is a front cover on the carrier.
The workpiece request in the middle (2) checks if there is a back cover on the lower part. The left request (1)
checks if the front cover is in its correct position on the carrier. When the front cover is in its correct position
and there is no back cover on it, the first two drilling holes are drilled into the left side of the front cover.
Then the X-axis moves to the right position and the two right drilling holes are drilled. After that, the carrier
leaves the application module iDrilling.

Design and function
16 © Festo Didactic CP Factory / CP Lab ° application module drilling
4.5 Process description
Start Conditions
All connections have been made properly
Starting position
The cylinder of the drilling unit must be in its upper end position
The workpiece queries must be set correctly.
The cylinder of the sliding unit must be in the left end position
Procedure
1. If a goods carrier with a workpiece is transported up to the stopper when the application is activated,
the goods carrier is stopped and an automatic sequence is started
2. The workpiece is interrogated, there must be a front shell on the goods carrier, there must be no back
shell on the front shell, the position of the front shell must be correct in the goods carrier
3. The drilling machines are switched on. Depending on the drill program, the X axis moves to the left.
4. The drilling unit moves downwards and drills two holes into the lower housing part
5. The drilling unit moves up again
6. The X axis moves to the right position, depending on the drill program.
7. The drilling unit moves downwards and drills the holes 3 and 4 into the lower housing part
8. The drilling unit moves up again and the drilling machines are switched off
9. Depending on the drill program, the X axis returns to its initial position
10. The application program is finished, the stopper switches downwards and the goods carrier leaves the
station.
For parameters for the sequence, see chapter Operation.

Design and function
© Festo Didactic CP Factory / CP Lab ° application module drilling 17
4.6 Electrical Connections
4.6.1 CECC I/O assignment
Inputs
Designation
Equipment identifier
Application
Application SysLink
X-axis left
+VN-BG1
KF1 / X2:0
I0.0
X-axis right
+VN-BG2
KF1 / X2:1
I0.1
0= Front cover right orientation
+VN-BG3
KF1 / X2:2
I0.2
0= Front cover available
+VN-BG4
KF1 / X2:3
I0.3
Z-axis top
+VN-BG5
KF1 / X2:4
I0.4
Z-axis down
+VN-BG6
KF1 / X2:5
I0.5
Reserve
I0.6
0= Back cover already available
+VN-BG7
KF1 / X2:7
I0.7
Not used
I1.0
Not used
I1.1
Not used
I1.2
Not used
I1.3
Not used
I1.4
Emergency stop active
+VN-XD1:24NA
I1.5

Design and function
18 © Festo Didactic CP Factory / CP Lab ° application module drilling
Outputs
Designation
Equipment identifier
Application
Application SysLink
X-axis to left
+VN-MB1
KF1 / X4:0
Q0.0
X-axis to right
+VN-MB2
KF1 / X4:1
Q0.1
Drill 1 via start-up current limiter 52Q1
+VN-QA3:IN
KF1 / X4:2
Q0.2
Drill 2 via start-up current limiter 52Q2
+VN-QA4:IN
KF1 / X4:3
Q0.3
Z-axis upward
+VN-MB5
KF1 / X4:4
Q0.4
Z-axis downward
+VN-MB6
KF1 / X4:5
Q0.5
Z-axis clamping open
+VN-MB7
KF1 / X4:6
Q0.6
Reserve

Start up
© Festo Didactic CP Factory / CP Lab ° application module drilling 19
5Start up
The application module iDrilling is delivered pre-assembled. You will receive
the application module and all its additional parts
All components, pipe connections and wirings are marked clearly in order to guarantee an unproblematic re-
establishment of all connections.
5.1 Workstation
For starting up the application module iDrilling, you need
the application module iDrilling
a basic module (linear, shunt, bypass) for the assembly of the module
a connection cable with Syslink plugs for the I/O box to the I/O terminal
5.2 Mechanical Setup
All components, pipe connections and wirings are marked clearly in order to guarantee an unproblematic re-
establishment of all connections. The graphics for the pneumatic and the electric connections are described
exemplarily as follows.

Start up
20 © Festo Didactic CP Factory / CP Lab ° application module drilling
5.2.1 Connection of application module
The mounting of an application module is very easy. At first, 2 slot nuts M5 are put into the front slot of the
front cross profile. Then two other slot nuts are put into the back slot of the profile. Afterwards the slot nuts
have to be adjusted to the distance of the application module profiles.
Put in slot nuts
Then you install the application module. The slot nuts must be placed now under the mounting brackets so
that the screws can be fixed.